Combustion Efficiency Control Systems

ABSTRACT

A high efficiency laminar flow burner system for proving a stream of heat energy including a supply input module for providing fuel and laminar streams of air to a combustion manifold. The laminar air delivery system includes a damper, a blower, and an air delivery controller. The air delivery controller receives an efficiency signal to control the flow of a laminar air intake stream by adjusting the damper. The combustion manifold includes an air-fuel mixing system, a stoichiometric unit, and a refractory unit each coupled to one another. The laminar air intake stream traveling from the supply input module passes through a stoichiometric unit body to meet with a first combustion stream from an air-fuel mixing chamber within the stoichiometric unit body to define a second combustion stream. The second combustion stream then travels across the refractory passageway to define a third combustion stream.

BACKGROUND

1. Field of the Invention

This application is Continuation of a Divisional application Ser. No.13/566,813, filed Aug. 3, 2012, which is a Divisional and claims thebenefit of a Continuation application Ser. No. 13/071,658 which claimsbenefit under 35 U.S.C. §120 of a Non-Provisional application Ser. No.12/790,912, filed May 31, 2010, entitled “A Laminar Flow CombustionSystem and Method for Enhancing Combustion Efficiency”, by inventorsTeodoro A Cantú et al., the entirety of the above referencedapplications are hereby incorporated by reference as if fully set forthherein.

2. Field of the Invention

The present invention generally relates to combustion systems forenhancing efficiency as streams of laminar air and fuel mix. Moreparticularly, but not by way of limitation, the present inventionrelates to a combustion system for generating an optimized combustionstream by directing a stream of preconditioned laminar air mixed with afuel through a combination of stoichiometric combustion stagingarrangements and refractory units.

3. Description of Related Art

The general concept of low nitrogen-oxide (NOx) burners is to produce aflame that provides heat energy though a high efficiency combustionprocess with minimal waste products arising from the combustion, namelyoxides of nitrogen of which form the basis for environmental pollutionsuch as acid rain and smog. The resulting heat energy is used in avariety of industrial applications such as for boilers in energygeneration; for furnaces employed in applications requiring high heatsuch as smelting metals, distilling chemicals, petrochemicals and gas;paper manufacturing; and for flaring oil and gas wells. Similarly, such“high efficiency” burners seek to minimize a combination of othercombustion waste products in addition to NOx such as oxides of carbon(COx) and total hydrocarbons (THC) among others to comply with federaland international governmental requirements especially for globalwarming prevention as well as to conserve natural resources bymaximizing the burn efficiency of the requisite raw materials forcombustion.

Presently, many high efficiency burners require various swirlingtechniques to maximize the efficiency of a high efficiency burner.Swirling is a widely used mixing process for homogenizing an air fuelmixture in the combustion process by which atomized fuel is introducedinto a turbulent stream of air. However, various swirling techniques areoften non-uniformly applied across the entire combustion chamber.Detrimentally, fuel and air can become drawn apart from the air fuelmixture to thereby compromise combustion efficiency as well as to spreadwaste fuel throughout the combustion chamber which requires routinelytaking the high efficiency burner out of commercial operation to performpreventative maintenance for structural damage. Moreover, turbulent orswirled air provides an aerodynamic drag-effect that generallyinterrupts the rate at which air is initially supplied to a combustionchamber, and therefore consequently decreasing the operationalefficiency of the burner. Furthermore, costly and often bulky low-wasteemissions monitoring equipment are integrated with effluent towers ofcurrent high efficiency burner systems to ensure operational efficiency.Additional costs incur as emissions monitoring equipment shorten theoperational time of such burners to ensure overall operation withinlow-waste emission requirements.

Unfortunately, there is no known device or method for successfullyproviding a “high efficiency” combustion system for leaving negligiblewaste products for sustained use with industrial applications withoutuse of swirling techniques or derivations of swirling techniques.Therefore, a need exists for a system and method for generating anoptimized combustion stream by directing a stream of preconditionedlaminar air with a fuel through a combination of stoichiometriccombustion staging arrangements and refractory units. There is also aneed for a system and method for quickly and accurately increasingcombustion efficiency for a various applications through linking aseries of interchangeable reaction efficiency modules to the system.Many other problems and disadvantages of the prior art will becomeapparent to one skilled in the art after comparing such prior art withthe present invention as herein described.

SUMMARY

Aspects of the present invention are found in a laminar flow burnersystem having a combustion manifold for establishing a combustionprocess that generates a high efficiency stream of heat energy. Thelaminar flow burner system includes a supply input module coupled to thecombustion manifold and provides fuel and laminar streams of airthereto. The combustion manifold includes at least one air-fuel mixingsystem, one stoichiometric unit, and one refractory unit each coupled toone another. A first combustion stream is established at the air-fuelmixing chamber system as fuel is discharged from a plurality ofinjectors to mix with the laminar air intake stream traveling along amixing chamber. In at least one aspect, the fuel exits from theplurality of injectors in a manner that is perpendicular to the laminarair intake stream. In one aspect, a pilot unit is provided within themixing chamber and includes an electrical resistor for igniting the fuelas the fuel contacts the hot resistor.

The stoichiometric combustion unit includes a staging passageway and astoichiometric unit body. A laminar air intake stream traveling from thesupply input module and along the staging passageway passes through astoichiometric unit body at a plurality of air intakes to meet and mixwith the first combustion stream within to thus define a secondcombustion stream for introduction from the stoichiometric unit to therefractory unit. A refractory unit body is composed of refractorymaterial to prevent absorption of heat energy to the refractory unit asthe second combustion stream travels across a refractory passageway todefine a third combustion stream. In one aspect, the third combustionstream exits the laminar burner system to thereby define an energyoutput for use with an energy consumption system.

In one aspect, a method for combusting air and fuel with a burner systemusing a laminar air intake stream is appreciated as follows. A laminarair intake stream is preconditioned prior to entering a combustionmanifold of the laminar burner system. The laminar air intake stream isdirected from the supply input module to an air-fuel mixing chambersystem of the combustion manifold. The air-fuel mixing chamber systemfeatures the injector device having the plurality of injectors and thepilot unit positioned adjacent to the injector device.

In one aspect, a first combustion stream is established within themixing chamber as the fuel is ejected from the plurality of injectorsperpendicular to the laminar air intake stream and continuously ignitedby the pilot unit as the pilot unit receives a voltage.

A second combustion stream is established within the stoichiometriccombustion unit. As such, a laminar air intake stream is directed fromthe supply input module through a staging passageway to a stoichiometricunit body each of the stoichiometric combustion unit. The secondcombustion stream is established within a stoichiometric channelway asthe laminar air intake stream from the staging passageway is injectedthrough a plurality of air intakes of the stoichiometric unit body asthe first combustion stream is directed from the mixing chamber throughthe stoichiometric channelway.

The second combustion stream is directed from the stoichiometric unitbody through a refractory unit to establish a third combustion stream.The third combustion stream exits the laminar burner system to therebydefine an energy output.

In one aspect, in addition to adjusting combustion efficiency throughcontrolling the input supply of laminar air and fuel, the combustionprocess established by the combustion manifold can be adjusted toaccurately modify combustion efficiency for various industrialapplications through linking a series of interchangeable reactionefficiency modules within the combustion manifold. Moreover, one supplyinput module can be interchanged for another of differing configurationto accommodate demand for laminar air intake streams as varyingquantities of reaction efficiency modules are either added to or removedfrom the combustion manifold.

In a further aspect of the present invention, for facilitating operationof a laminar burner system, a combustion efficiency control system isintegrated with a laminar burner system. The combustion efficiencycontrol system provides operational instructions for optimizing a highefficiency combustion process in the delivery of thermal energy to anenergy consumption system coupled to the laminar burner system.

Other aspects, advantages, and novel features of the present inventionwill become apparent from the detailed description of the presentinvention when considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example and not bylimitation in the accompanying figures, in which like referencesindicate similar elements, and in which:

FIG. 1 is an schematic view from the side illustrating a burner systemfor generating heat energy by directing a stream of laminar air with afuel from a supply input module through a combustion manifold having atleast an air-fuel mixing chamber, a stoichiometric combustion unit, anda refractory unit;

FIG. 2 is a partially exploded, schematic view from the sideillustrating a laminar burner system;

FIG. 3 is an isometric view from the side of one embodiment of a laminarair delivery system for a burner system featuring an interchangeablesupply input module; FIG. 3 a is an isometric from the side illustratingan interior viewer for observing operations within the supply inputmodule;

FIG. 4 is a flow diagram of a method for combustion with a laminarburner system using a laminar air intake stream;

FIG. 5 is a schematic view from the side illustrating one embodiment ofa combustion efficiency control system for a laminar burner system, thecombustion efficiency control system controlling laminar air and fuelflows for enhancing combustion efficiency of the laminar burner system;

FIG. 6 is a flow diagram of method for controlling combustion efficiencyfor a laminar burner system; and

FIG. 7 is a schematic view from the side illustrating one embodiment ofa burner system for quickly and accurately modifying combustionefficiency for a various applications through linking a series ofinterchangeable reaction efficiency modules to the system, FIG. 7 a isan isometric view showing a plurality of laminar staging supply linesextending outwardly from an air receiving port.

Skilled artisans appreciate that elements in the Figures are illustratedfor simplicity and clarity and have not necessarily been drawn to scale.For example, the dimensions of some of the elements in the Figures maybe exaggerated relative to the other elements to help improveunderstanding of the embodiments of the present invention.

DETAILED DESCRIPTION

For a more complete understanding of the present invention, preferredembodiments of the present invention are illustrated in the Figures.Like numerals being used to refer to like and corresponding parts of thevarious accompanying drawings. It is to be understood that the disclosedembodiments are merely exemplary of the invention, which may be embodiedin various forms.

FIGS. 1-3, 5, and 7 generally illustrate a laminar flow burner system 5having a combustion manifold 70 for applying a combustion process thatgenerates a high efficiency stream of heat energy. The laminar flowburner system 5 includes a supply input module 20 coupled to andproviding fuel and laminar streams of air to the combustion manifold 70.The resulting high efficiency combustion stream is optimized for avariety of industrial applications such as for boilers in energygeneration including heat, mechanical, and electric energy; propulsionsystems; for furnaces employed in applications requiring high heat suchas smelting metals and alloys, distilling chemicals, petrochemicals andgas; paper manufacturing; and for flaring oil and gas wells.

Accordingly, in at least one embodiment, the combustion processestablished by the combustion manifold 70 can be adjusted to accuratelymodify combustion efficiency for various industrial applications throughlinking a series of interchangeable reaction efficiency modules 800within the combustion manifold 70 in addition to adjusting combustionefficiency through controlling the input supply of laminar air and fuel.Moreover, one supply input module 20 may be interchanged for another ofdiffering configuration to accommodate varying quantities of reactionefficiency modules 800.

In this application, the terms “air” or “atmospheric air” refer togasses surrounding the earth that provide oxygen as a fuel forcombustion. In this application, the term “false start” refers to thetermination of a combustion process as a pilot's ignition flame is blownout as a result of high fluid flow rates that arise from any combinationof air flow or fuel flow into a combustion chamber of a burner. In thisapplication, the term “stoichiometric” refers to a qualitativerelationship of air and fuel to that of remaining combustion wasteproducts, (examples referenced above such as, among others carbondioxide), after undergoing chemical transformation from a gas statethrough an oxidation process during combustion where there is negligibleor no amounts of organic carbon and other waste products left, forexample with measured carbon dioxide emissions less than one part permillion. In this application, the term “refractory” refers to a materialfor high-temperature operational use while exposed to temperatures atleast above 1,000° C. In this application, the terms N^(th) and N^(th)−1respectively refer to: for any desired number of reaction efficiencyoptimization modules, sequentially the last reaction efficiencyoptimization module in a series of reaction efficiency optimizationmodules that define a combustion manifold and a reaction efficiencyoptimization module sequentially before the last reaction efficiencyoptimization module.

Specifically as viewed in FIGS. 1-3, 5, and 7, the laminar burner system5 includes a damper 21 in fluid communication with a blower 25 such thatthe damper 21 controls the flow of atmospheric air to the blower 25. Inthat turbulent or “swirled” air techniques commonly employed by highefficiency burners provide a drag-effect that interrupts the rate atwhich air is initially supplied to a combustion chamber, the damper 21in the present invention variably controls the flow rate of atmosphericair or, optionally, oxygen responsive to the combustion process executedby the combustion manifold 70 downstream. Accordingly, in general, alaminar air delivery system 22 that includes the damper 21 and theblower 25 that cooperatively operate to generate a laminar air intakestream for the laminar burner system 5.

Referring to FIG. 1, the laminar burner system 5 includes the laminarair delivery system 22, the supply input module 20, and the combustionmanifold 70. In operation, atmospheric air or, optionally, oxygen isdrawn through the laminar air delivery system 22, across the supplyinput module 20, and then introduced to the combustion manifold 70 as alaminar air intake stream. Similarly, fuel is directed across the fueldelivery system 30, through the supply input module 20, and dischargedwithin the combustion manifold 70 to mix with the laminar air intakestream. Illustratively, in one embodiment, ten parts of laminar air toone part of fuel is mixed within the combustion manifold 70.

As shown in FIGS. 1, 3, 5, and 7, the laminar air delivery system 22includes a damper 21 for variably collecting atmospheric air. The damper21 is of a type well known in the industry. As discussed further below,to achieve optimal levels of combustion efficiency, the damper 21 in atleast one embodiment is operatively integrated with a combustionefficiency control system 888. Through efficiency signals 88 asillustrated in FIG. 5, the combustion efficiency control system 888regulates the rate of atmospheric air collection by the damper 21.

Atmospheric air collected by the damper 21 then travels across adelivery line 23 to a blower 25. Although shown positioned in FIG. 3 ata 90° angle relative to the blower 25, those of ordinary skill in theart will readily recognize that the delivery line 23 can be positionedat any angle with respect to the blower 25.

The blower 25 operatively accelerates the air toward the combustionmanifold 70. The blower is of a type widely used in the industry, suchas a centrifugal blower or fan. Air is pushed by the blower 25 throughan air feed line 27 toward the supply input module 20. In at least oneembodiment, the air feed line 27 is a conduit. In another embodiment,the air feed line 27 is a tube. With the air exiting the blower 25, theair feed line 27, in part, operatively establishes a laminar air intakeflow stream for use with the combustion process applied within thecombustion manifold 70. The air feed line 27 couples to the supply inletchamber 20 via the air receiving port 28. The air receiving port 28provides a sealed interface for fluid communication between the air feedline 27 and the supply inlet chamber 20.

Referring to FIGS. 1, 3, and 5, the fuel is directed across the fueldelivery system 30. In at least one embodiment, the fuel includes one ormore fuels selected from the group consisting of: natural gas, processedmethane, and natural gas liquids such as propane, butane, pentane, heavyfuel oil, light distillate oil and biogas. Those of ordinary skill inthe art will readily recognize any fuel suitable for combusting with airor oxygen as the laminar burner system 5 operates in either low or highoxygen environments.

As illustrated in FIGS. 3 and 5, the fuel delivery system 30 includes afuel passageway 34. The fuel passageway 34 is a hollow body forchanneling fuel to the combustion manifold 70. In one embodiment, thefuel passageway 34 comprises a tube. In one embodiment, the fuelpassageway 34 comprises a conduit. In operation, fuel within the fuelpassageway 34 travels from a fuel source (not shown) toward the supplyinput module 20. Optionally, as discussed further below in reference toFIG. 5, a fuel controller unit 74 features a fuel passageway valve 74 acoupled to the fuel passageway 34 to variably supply fuel to thecombustion manifold 70.

The supply input module 20 features an alignment plate 72 by which thefuel passageway 34 is aligned and secured thereto. Specifically, in FIG.1, the center of the alignment plate 72 defines an alignment axis 777 bywhich the fuel passageway 34 is positioned and mounted to the alignmentplate 72 with respect to the alignment axis 777.

Accordingly, fuel travels from the supply input module 20 toward thecombustion manifold 70 within a hollow bodied, injector device 31 as theinjector device 31 provided by the fuel delivery system 30 extendsoutwardly from the alignment plate 72. In particular, shown in FIG. 1,the injector device 31 extends from alignment plate 72 along an air-fuelmixing chamber system 40 provided by the combustion manifold 70. Thoseof ordinary skill in the art will readily recognize that the injectordevice 31 can either be an integral portion of the fuel passageway 34 orseparate unit in fluid communication with the fuel passageway 34.

The injector device 31 defines a plurality of injectors 32. In oneembodiment, the injector device 31 defines a multiplicity of injectors32, such as greater than five hundred injectors. Optionally, tofacilitate a desired overall aerodynamic configuration for the injectordevice 31, at least one mixing outlet combustion enhancer 33 couples toand is rendered in fluid communication with the injector device 31thereby enhancing combustion for the laminar flow burner system 5. Forexample, as shown for the embodiment of FIG. 1, the mixing outletcombustion enhancer 33 comprises a conic configuration that couples tothe flat end of a tube defining the injector device 31 to preventaccumulation of low pressure at the flat end thereby further promotingthe mixture of fuel with the laminar stream of air within the air-fuelmixing chamber.

In operation, fuel traveling within the injector device 31 exits throughthe injectors 32 to mix with a laminar air intake stream near theinjector device 31 as the laminar air intake stream travels the alongthe air-fuel mixing chamber system 40. In at least one embodiment, as itdefines the centerline for both the injector device 31 and the alignmentplate 72, the alignment axis 777 is a spatial reference for orientatingthe ejected fuel as it combines with the laminar air-intake stream.Accordingly, as discussed in further detail below, fuel exits theinjector device 31 to mix with the laminar air intake stream to form afirst combustion stream. The fuel exits the injector device 31perpendicular to the laminar air-intake stream traveling along theair-fuel mixing chamber system 40 to define a first combustion stream.Specifically, the positive pressure of air within the air-fuel mixingchamber system 40 is low and slow moving such that fuel exits theinjector device 31 perpendicular to the laminar air-intake stream. Inone alternative embodiment, the fuel exits the injector device 31substantially perpendicular to the laminar air-intake stream travelingalong the air-fuel mixing chamber system 40 to define a first combustionstream.

Shown in FIG. 3, the alignment plate further defines a plurality ofinlet ports 29 that are variably exposed via inlet actuators 89 toselectively supply the laminar air-intake stream to the combustionmanifold 70 at a desired quantity and flow rate. As shown, each inletport 29 is characteristically small and narrow relative to the alignmentplate 72 and configured to establish laminar fluid flow therethrough. Tothereby increase energy output of the laminar burner system 5, those ofordinary skill in the art will readily recognize any suitable, wellknown size and configuration of each inlet port 29 to increase eitherthe amount or flow rate of the laminar air flow stream flowingtherethrough.

Illustratively, in FIGS. 1, 3, 3 a, and 5, a plurality of first inletports 29 a and a plurality of second inlet ports 29 b correspondinglysupply laminar streams of air from the supply input module 20 to theair-fuel mixing chamber system 40 and a stoichiometric combustion unit50, respectively. In the illustration, each first and second inlet port29 a, 29 b is operatively engaged with a corresponding sealing door 89′from a respective inlet actuator 89. The sealing door 89′ is renderedfrom a closed position to an open position to expose the correspondingfirst and second inlet ports 29 a, 29 b for flow of the laminarair-intake stream therethrough. As the sealing door 89′ moves from aclosed position toward an open position, air flow through thecorresponding inlet port 29 proportionately increases to operativelyincrease the energy output of the laminar burner system 5.

In one embodiment, the inlet actuator 89 comprises a linear actuator ofa type well known in the industry for variably rendering the sealingdoor 89′ to expose the first inlet port 29 a for selectively permittingfluid flow of the laminar air-intake stream therethrough and toward theair-fuel mixing chamber system 40. Similarly, in the continuingillustration, the inlet actuator 89 renders the sealing door to variablyopen the second inlet port 29 b for permitting fluid flow of laminar airintake stream therethrough and toward the stoichiometric combustion unit50. As discussed further below in reference to FIG. 5, the inletactuator 89 is responsive to efficiency signals 88 for variablycontrolling the flow rate of the laminar air-intake stream to optimizecombustion efficiency.

The supply input module 20 further includes an air receiving port 28.Operatively, the supply input module 20 receives air from the air feedline 27 of the laminar air delivery system 22 at the air receiving port28. In one embodiment, the air receiving port 28 diffuses the airreceived from the laminar air delivery system 22 across the supply inputmodule 20.

Illustratively, the air receiving port 28 for the embodiment of FIG. 7diffuses air received from the laminar air delivery system 22 across aplurality of laminar staging supply lines 199 to direct a plurality oflaminar air intake streams to the combustion manifold 70 that features aplurality of interchangeable reaction efficiency modules 800.

FIG. 3 a shows an interior viewer 26 b for observing operations withinthe air-fuel mixing chamber 40 and the supply input module 20 of FIG. 3.As shown, the interior viewer 26 b is composed of either transparent orsemi-transparent material, such as, among others, semi-transparenttinting and partial mirroring. The interior viewer 26 b is held in placeand positioned within the supply input module 20 by a viewer support 26a. In operation, an observer can identify many critical aspects relatingto combustion, such as, among others, the flame color through the inletports 29 a, 29 b past the alignment plate 72 to visually gaugecombustion efficiency; the general operability of each inlet actuator89; and positioning with respect to the alignment axis 777 as well asthe structural integrity of the air receiving port 28 and the fuelpassageway 34 while secured to the supply input module 20.Illustratively, in one embodiment, an observer can identify through theinterior viewer 26 b the combustion flame color adjacent to a pilotunit. In one embodiment, a boiler prism sensor of a type well known inthe industry is disposed within the mixing chamber 44 to gaugecombustion efficiency.

In one embodiment, based on the flame color viewed, an observer canmanually adjust the laminar air intake stream to correspondingly changecombustion efficiency of the laminar burner system 5. For example amongothers, by manually interfacing with the combustion efficiency controlsystem 888, the observer adjusts the corresponding inlet actuators 89 tochange the opening of the desired inlet port 29. Illustratively, in oneembodiment, ten parts of laminar air to one part of fuel is mixed withinthe combustion manifold 70 so that the color of the resulting combustionstreams reach a very bright blue color indicative of an oxidationprocess where there is no more organic carbon left so that the emissionoutput reaches a carbon dioxide level of one part per million or below.

With reference to FIGS. 1-3, 5, and 7, the combustion manifold 70 of thelaminar burner system 5 is in fluid communication with the supply inputmodule 20 to receive the laminar air intake stream and the fuel from thesupply input module 20 for establishing a high efficiency combustionprocess. The combustion manifold 70 secures to and extends outwardlyfrom the alignment plate 72. Moreover, the combustion manifold 70 ispositioned with respect to the alignment axis 777.

Operatively, for purposes of illustration, the combustion manifold 70can be divided in to a stoichiometric staging arrangement 45 and arefractory unit 60. Moreover, in FIG. 1, the stoichiometric stagingarrangement 45 includes at least one air-fuel mixing chamber system 40and at least one stoichiometric combustion unit 50.

In particular, the air-fuel mixing chamber system 40 includes a mixingchamber body 42. The mixing chamber body 42 is the innermost arrangementwithin the combustion manifold 70. The mixing chamber body 42 is fixedto the alignment plate 72 and is in fluid communication with first inletports 29 a for receiving a laminar air intake stream from the supplyinput module 20. The mixing chamber body 42 is positioned with respectto the alignment axis 777 and the injector device 31.

As shown in FIG. 1, the mixing chamber body 42 defines a mixing chamber44. In operation, fuel traveling within the injector device 31 exitsthrough the plurality of injectors 32 to mix with a laminar air intakestream near the injector device 31 as the laminar air intake streamtravels the away from the first inlet port 29 and along the mixingchamber 44.

Referring to FIGS. 1, 3, 3 a, and 5, the air-fuel mixing chamber system40 further includes a pilot unit 35 and a combustion sensor/controllerunit 37 each positioned adjacent to the injector device 31 with respectto the alignment axis 777 and fixed to the alignment plate 72. Thesensor/controller unit 37 is electrically coupled to the pilot unit 35and the inlet actuators 89 for variably closing the respective inletports 29 and the damper 21. Moreover, the pilot unit 35 is selectivelyengaged by the sensor/controller unit 37 to ignite the nearby fuel basedon predetermined wavelengths of light detected by the sensor/controllerunit 37. The predetermined wavelengths of light correspond to the flameintensity of a first combustion stream formed within the mixing chamber44.

To avoid the abrupt, unwanted termination of combustion associated witha false start within the laminar burner system 5, the pilot unit 35remains engaged continuously or, alternatively, for periods greater thantwo minutes. Specifically, the pilot unit 35 includes an electricalresistor for igniting the fuel as the fuel contacts the hot resistor. Inone embodiment, the pilot unit 35 includes outwardly extendingprojections 35′ to facilitate rapid transfer of heat energy to the fuel.The pilot unit 35 operatively receives a voltage to generate heat energyfor any desired period. The voltage is continuously applied to engagethe pilot unit 35 thereby ensuring uninterrupted fuel ignition tooperate the laminar burner system 5 as desired.

Illustratively, in one embodiment, about one minute elapses for theresistor to warm and thus engage the pilot unit 35. The pilot unit 35receives fuel from adjacent injectors 32 to ignite and establish aflame. Accordingly, the sensor/controller unit 37 detects variouspredetermined wavelengths of light indicative of the flame color of afirst combustion stream formed within the mixing chamber 44 as the fueland the laminar air intake stream are combined. The pilot unit 35 isdisengaged by the sensor/controller 37 as the sensor/controller 37detects a predetermined wavelength of light to furthermore increase theair and fuel supply by controlling any combination of the damper 21′,the fuel passageway valve 74 a, and array of inlet ports 29. On average,in one embodiment, a period of seventy-five seconds elapses for thepilot unit 35 to fully engage and disengage in the manner describedabove.

Furthermore, in one embodiment, the electrical resistor comprises avariable resistor. In operation, the electrically engaged variableresistor ignites the fuel on contact. As such, in at least oneembodiment, the variable resistor accommodates controlling fuel ignitionbased on a timer to selectively blow out or ignite the pilot unit 35.Moreover, in one embodiment, the resistor is composed of a metal ormetal alloy, such as Ni—Cr or Al alloys, Pt, Cu, Cr metals and alloys.In another embodiment, the resistor is composed of a high temperatureceramic, such as among others nitrides, borides, carbides and oxides ofAl, Ti, Mo and Zr.

As discussed below, the sensor/controller unit 37 emits and receivesefficiency signals 88 associated with the combustion efficiency controlsystem 888. The sensor/controller unit 37 detects various predeterminedwavelengths of light indicative of the flame intensity of a firstcombustion stream formed within the mixing chamber 44 as the fuel andthe laminar air intake stream are combined. Variations in flame colorcorrespond to different levels of combustion efficiency achieved by thelaminar burner system 5. Based on measured light wavelengths, thesensor/controller unit 37 emits an efficiency signal 88 to thecombustion efficiency control system 888 to thereby adjust combustionefficiency. Accordingly, by way of illustration, the combustionefficiency control system 888 can emit an efficiency signal 88 forreceipt by the sensor/controller unit 37 or, alternatively, directly bythe inlet actuators 89 to automatically adjust the laminar air intakestream to correspondingly change combustion efficiency by changing thepilot unit's 35 period of operative engagement as a result of thesensor/controller unit 37 reading wavelengths indicative of successfulcombustion as the pilot unit 35 is engaged.

Operatively, as discussed above, a laminar air intake stream ispreconditioned prior to entering the combustion manifold 70 of thelaminar burner system 5, such as, among others, preconditioned for aspecific quantity, flow rate or temperature. In one embodiment, thelaminar air intake stream is preconditioned as ambient air, oralternatively oxygen, is forced through laminar air delivery system 22to the supply input module 20. At the air receiving port 28 of thesupply input module 20, the laminar air intake stream is separated to beprovided to the combustion manifold 70 at different stages of thecombustion process.

For example, the laminar air intake stream is divided to be provided tothe air-fuel mixing chamber system 40 and to the stoichiometriccombustion unit 50 via the first inlet ports 29 a and the second inletports 29 b, respectively. The air-fuel mixing chamber system 40 is influid communication with the supply input module 20 and includes themixing chamber 44 and the injector device 31 extending within the mixingchamber 44. At the air-fuel mixing chamber system 40, a first combustionstream is established as fuel is discharged from the injectors 32 to mixwith the laminar air intake stream traveling along the mixing chamber44. In one embodiment, the fuel exits the injector device 31perpendicular to the laminar air intake stream.

Referring to FIG. 1, the stoichiometric combustion unit 50 is in fluidcommunication with the supply input module 20 and with the air-fuelmixing chamber system 40. For the embodiment of FIG. 1, thestoichiometric combustion unit 50 includes a combustion unit body 46.The combustion unit body 46 is secured to the alignment plate 72 andpositioned with respect to the alignment axis 777 so that the air-fuelmixing chamber 40 and the injector device 35 are positioned within thecombustion unit body 46.

As shown in FIG. 1, the spatial gap between the combustion unit body 46and the mixing chamber body 42 defines a staging passageway 49 fordirecting the laminar air intake stream therethrough. Accordingly, thesecond inlet ports 29 b at the alignment plate 72 are positioned tosupply the laminar air intake stream to the staging passageway 49.

Alternatively, as shown in FIG. 5, a manifold binder body 24 can besubstituted for the above referenced combustion unit body 46 so that thespatial gap between the manifold binder body 24 and the mixing chamberbody 42 defines a staging passageway 49 for directing the laminar airintake stream therethrough. Those of ordinary skill in the art willreadily recognize various embodiments where the manifold binder body 24can either replace or complement other container bodies whilestructurally supporting the combustion manifold. For example, theembodiments of FIGS. 1 and 7 show the manifold binder body 24structurally cooperating with other container bodies to support thecombustion manifold 70 as reaction efficiency modules 800 are eitheradded or removed from the laminar burner system 5. The embodiment ofFIG. 2 shows a combination the manifold binder body 24 and the mixingchamber body 42 cooperatively providing structural support to thecombustion manifold 70. The embodiment of FIG. 5 shows the manifoldbinder body 24 as replacing other container bodies to structurallysupport the combustion manifold 70.

The stoichiometric combustion unit 50 further includes a stoichiometricunit body 51. The stoichiometric body 51 a hollow body that is in fluidcommunication with the staging passageway 49 and with the mixing chamber44. The stoichiometric unit body 51 defines a plurality of air intakes52. The laminar air intake stream travels from the staging passageway 49and enters in the stoichiometric unit body 51 through the plurality ofair intakes 52. Within a stoichiometric channelway 51 a defined by thehollow of the stoichiometric unit body 51, as shown in FIG. 2, thelaminar air intake stream from the stating passageway 49 combines withthe first combustion stream that is exiting the mixing chamber 44 andtraveling within a stoichiometric channelway 51 a to form a secondcombustion stream. In effect, the air intake stream introduced throughthe air intakes 52 acts as an oxidizer fuel for further igniting thefirst combustion stream to thus form the second combustion stream havinga higher temperature and less combustion waste products than the firstcombustion stream.

In at least one embodiment, a mixing plate 57 and a stoichiometric plate58 are disposed on opposing sides of the stoichiometric unit body 51.The mixing plate 57 and the stoichiometric plate 58 each align thestoichiometric unit body 51 with respect to the alignment axis 777 aswell as facilitate requisite fluid flow for the combustion process ofthe laminar burner system 5. In particular, the mixing plate 57 definesa mixing chamber outlet 55 in fluid communication with the mixingchamber 44 of the air-fuel mixing chamber system 40. The firstcombustion stream from the mixing chamber 44 is received at the mixingchamber outlet 55 and directed through the stoichiometric unit body 51to the refractory unit 60. Similarly, the stoichiometric plate 58defines a stoichiometric outlet 59 in fluid communication with thestoichiometric unit body 51. A second combustion stream exiting thestoichiometric unit body 51 is received at the stoichiometric outlet 55and directed through the refractory unit 60.

In summary, establishing a second combustion stream with thestoichiometric combustion unit 50 is as follows. The stoichiometriccombustion unit 50 is in fluid communication with the supply inputmodule 20 and with the air-fuel mixing chamber system 40. Thestoichiometric combustion unit 50 includes the staging passageway 49 andthe stoichiometric unit body 51. A laminar air intake stream travelingalong the staging passageway 49 passes through the stoichiometric unitbody 51 at the air intakes 52 to meet with the first combustion streamwithin to define a second combustion stream for introduction to therefractory unit 60.

Referring to FIG. 1, the refractory unit 60 is in fluid communicationwith the stoichiometric combustion unit 50. In particular, therefractory unit 60 communicates with the stoichiometric combustion unit50 at the stoichiometric outlet 59.

The refractory unit 60 features a refractory unit body 47. Therefractory unit body 47 is positioned between the stoichiometric plate58 and an outlet plate 61 at the opposing end and terminus of thelaminar burner system 5 for the embodiment of FIG. 1. In at least oneembodiment, the refractory unit body 47 is composed of refractorymaterial to prevent absorption of heat energy to the refractory unit 60as the third combustion stream travels across the refractory passageway66. In one embodiment, the refractory unit body 47 is composed ofrefractory material of a type well known in the industry, such as one ormore selected from the group consisting of: tungsten, molybdenum,aluminum oxide, aluminosilicates, silicon carbide, graphite, silica,magnesia, calcium oxides, and zirconia.

Shown in FIG. 1, the refractory unit body 47 defines a refractorypassageway 66. The refractory passageway 66 extends through therefractory unit 60 to communicate with the stoichiometric outlet 59 anda burner system outlet 63 defined by the outlet plate 61 at the terminusof the combustion manifold 70 of FIG. 1.

Operationally, the second combustion stream travels from within thestoichiometric unit body 51 across the refractory passageway 66 todefine a third combustion stream. In particular, in one embodiment, therefractory passageway 66 is conically shaped with the vertex emergingfrom the stoichiometric outlet 59 and the curved conic surface expandingoutwardly through the refractory unit body 51.

Similar to a jet or rocket nozzle, the volumetrically expanding conicsurface relieves high pressure build-up characteristic of the secondcombustion stream while accelerating the combustion gasses to thus forma third combustion stream. In effect, the third combustion streampromotes increased acceleration of combustion gases exiting the laminarburner system 5. Accordingly, increased exhaust acceleration providesfor the continuous drawing of the fuel, the laminar intake stream, aswell as the first, the second and the third combustion streams quicklythrough the laminar burner system without requiring additional externalwork during the combustion process. In at least one embodiment, theoutward expansion of the conic surface defining the refractorypassageway 66 is predetermined and promotes increased exhaustacceleration with negligible loss of heat energy.

Operatively, as illustrated in FIGS. 5 and 7, a refractory unit 60 iscoupled to and in fluid communication with an energy consumption system75. In one embodiment, the refractory unit 60 is releasably coupled tothe energy consumption system 75. The energy consumption system 75 usesthe heat energy output generated by the laminar burner system 5 for avariety of applications. Examples of the energy consumption system 75that use the laminar burner system 5 include, among others, boilers inenergy generation including heat, mechanical, and electric energy;propulsion systems including jet, rocket, and steam propulsion systems;furnaces employed in applications requiring high heat such as smeltingmetals and alloys, distilling chemicals, petrochemicals and gases; papermanufacturing devices; and flaring devices for oil and gas wells.

Referring to FIG. 4, a method for combusting air and fuel with a burnersystem using a laminar air intake stream 100 may be appreciated asfollows. In step 100, a laminar air intake stream is preconditionedprior to entering a combustion manifold 70 of the laminar burner system5. The laminar air intake stream in step 103 is directed from the supplyinput module 20 to an air-fuel mixing chamber system 40. The air-fuelmixing chamber system 40 features the injector device 31 having theplurality of injectors 31 and the pilot unit 35 positioned adjacent tothe injector device 31.

In step 105, a first combustion stream is established within the mixingchamber 44. In particular, the fuel is ejected from the plurality ofinjectors 31 to mix with the laminar air intake stream and ignited bythe pilot unit 35 as the pilot unit 35 receives a voltage. The laminarair intake stream is directed from the supply input module 20 through astaging passageway 49 to a stoichiometric unit body 51.

In step 107, a second combustion stream is established within thestoichiometric combustion unit 50. Specifically, the laminar air intakestream from the staging passageway 49 is injected through the pluralityof air intakes 52 of the stoichiometric unit body 51 as the firstcombustion stream is directed through the stoichiometric channelway 51a. In step 109, the second combustion stream is directed from thestoichiometric unit body 51 through a refractory unit 60 to establish athird combustion stream. In at least one exemplary method, the thirdcombustion stream exits the laminar burner system 5 to define an energyoutput for use with an energy consumption system 75.

With reference to FIG. 7, a series of interchangeable reactionefficiency modules 800 are releasably coupled with a combustion manifold70 for adjustably increasing combustion efficiency to accommodate avariety of industrial applications. In FIG. 7, a laminar burner system 5includes a supply input module 20 and a combustion manifold 70 that isin fluid communication with the supply input module 20. The supply inputmodule 20 provides fuel and a laminar air intake stream to thecombustion manifold 70.

As shown, the combustion manifold 70 includes an air-fuel mixing chamber40 in fluid communication with the supply input module 20. As describedabove, the air-fuel mixing chamber 40 includes a mixing chamber and aninjector device extending within the mixing chamber. In operation, fuelexits the injector device to mix with the laminar air intake stream toform a first combustion stream.

The combustion manifold 70 further includes a first reaction efficiencyoptimization module 800. The first reaction efficiency optimizationmodule 800 includes a first stoichiometric combustion unit in fluidcommunication with the supply input module 20 via a laminar stagingsupply line 199 provided by the air-fuel mixing chamber system 40. Thefirst stoichiometric combustion unit includes a stoichiometric unitbody, whereby a laminar air intake stream traveling along the laminarstaging supply line 199 passes through the stoichiometric unit body tomeet the first combustion stream within the stoichiometric unit body todefine a second combustion stream.

In one embodiment, the first reaction efficiency optimization module 800further includes a refractory unit. The refractory unit is in fluidcommunication with the stoichiometric combustion unit and includes arefractory passageway. In operation, the second combustion streamtravels from within the stoichiometric unit body across the refractorypassageway to define a third combustion stream.

For the embodiment of FIG. 7, the combustion manifold 70 includes asecond reaction efficiency optimization module 800′ that is releasablycoupled to the first reaction efficiency optimization module 800′ and influid communication with the supply input module 20 via staging supplylines 199. As shown, the second reaction efficiency optimization module800′ includes a stoichiometric unit body and the staging supply lines199.

Operatively, a laminar air intake stream traveling along the stagingsupply lines 199 passes through the stoichiometric unit body to meet thethird combustion stream within the stoichiometric unit body to define afourth combustion stream. Optionally, although not provided for theembodiment of FIG. 7, the second reaction efficiency optimization module800′ in other embodiments further includes a refractory unit in fluidcommunication with the stoichiometric unit body, whereby the fourthcombustion stream travels from within the stoichiometric unit bodythrough the refractory unit to define a fifth combustion stream.

As shown, for the embodiment of FIG. 7, the combustion manifold 70includes an N^(th) reaction efficiency optimization module 800″ that isreleasably coupled to the second reaction efficiency optimization module800′ and in fluid communication with the supply input module 20 viastaging supply lines 199. Recall that “N^(th)” refers to sequentiallythe last reaction efficiency optimization module in a series of reactionefficiency optimization modules that define a combustion manifold.Therefore, in the illustration, the N^(th) reaction efficiencyoptimization module 800″ represents the last of any desired number ofreaction efficiency optimization modules after the first reactionefficiency optimization module 800 but not necessarily immediately afterthe first reaction efficiency optimization module 800, for example,among others, the N^(th) reaction efficiency optimization module 800″can represent the second or thirty-seventh reaction efficiencyoptimization module.

As shown, the N^(th) reaction efficiency optimization module 800″includes a stoichiometric unit body and staging supply lines 199.Operatively, a laminar air intake stream traveling within the stagingsupply lines 199 passes through the stoichiometric unit body to meetwith the previously generated combustion stream within thestoichiometric unit body to define an N^(th)−1 combustion stream.

The N^(th) reaction efficiency optimization 800″ module further includesa refractory unit. The refractory unit is in fluid communication withthe stoichiometric combustion unit and includes a refractory passageway.In operation, the N^(th)−1 combustion stream travels from within thestoichiometric unit body across the refractory passageway to define anN^(th) combustion stream. Accordingly, a desired combustion stream or,as referenced in the continuing illustration, N^(th) combustion streamproduced by the laminar burner system 5 defines an energy output. Theenergy output is delivered to an energy consumption system 75 for usewith a wide variety of industrial applications.

Furthermore, in one embodiment, a supply input module 20 of oneconfiguration can be exchanged for another of differing configuration toaccommodate demand for laminar air intake streams as varying quantitiesof reaction efficiency modules are either added or removed from thecombustion manifold to achieve a desired combustion output. The supplyinput module 20 includes an air receiving port 28, an alignment plate72, and a plurality of laminar staging supply lines 199 positionedtherebetween.

FIG. 7 a shows a plurality of laminar staging supply lines 199 extendingoutwardly from the air receiving port 28. In effect the laminar stagingsupply lines 199 and the above referenced staging passageway 49 areidentical in that they each operate to provide laminar air intakestreams from the supply input module 20 to the combustion manifold 70.In one embodiment, the staging passageway 49 is integral with thecombustion manifold 70 whereas the laminar staging supply lines 199 areconfigured to be removable from the combustion manifold 70.

The air receiving port 28 includes a plurality of sealed openings 28′.In operation, each seal from the sealed openings 28′ can be eitherremoved or added to accommodate insertion of a corresponding laminarstaging supply line 199 at the exposed opening to thus receive a laminarair intake stream from the air receiving port 28. Seals can be removedor added depending on the desired quantity of laminar staging supplylines 199 for delivering laminar air intake streams to the combustionmanifold 70.

One supply input module with one predetermined quantity of sealedopenings 28′ can be interchanged with another supply input module with adifferent predetermined quantity of sealed openings 28′. Thus, onesupply input module for supplying a predefined number of laminar stagingsupply lines to the combustion manifold is interchangeable with anothersupply input module for supplying a different number of laminar stagingsupply lines.

A method for combusting air and fuel with a laminar burner system isappreciated as follows. An N^(th) reaction efficiency optimizationmodule 800″ is coupled to a first reaction efficiency optimizationmodule 800. The first and N^(th) reaction efficiency optimizationmodules 800, 800″ each couple to the laminar burner system 5. In oneexemplary method, the first reaction efficiency optimization module 800couples to the laminar burner system 5 as the N^(th) reaction efficiencyoptimization module 800″ couples to the first reaction efficiencyoptimization module 800. In many embodiments of the method, a pluralityof efficiency optimization modules are coupled in series between theN^(th) reaction efficiency optimization module 800″ and the firstreaction efficiency optimization module 800.

The laminar air intake stream from the supply input module 20 isdirected to an air-fuel mixing chamber system 40 that includes a pilotunit and an injector device positioned adjacent to the pilot unit andhaving a plurality of injectors. The laminar air intake stream ispreconditioned prior to entering a combustion manifold 70 of the laminarburner system 5. A first combustion stream is established within themixing chamber in the same manner described above.

Another laminar air intake stream is directed from the supply inputmodule 20 through a laminar staging supply line 199 to a stoichiometriccombustion unit of the first reaction efficiency optimization module800. A second combustion stream is established within the stoichiometriccombustion unit in the same manner as described above. The secondcombustion stream is directed from the stoichiometric unit body througha refractory unit provided by the first reaction efficiency optimizationmodule 800 to establish a third combustion stream.

In at least one embodiment, another laminar air intake stream isdirected from the supply input module 20 to a stoichiometric unit bodyof the N^(th) reaction efficiency optimization module 800″ to meet thethird combustion stream within to define a N^(th) combustion streamwhereby the N^(th) combustion stream defines an energy output for thelaminar burner system 5. In other embodiments including the embodimentof FIG. 7, the combustion process executed by the combustion manifold 70includes at least a second reaction efficiency optimization module 800′and resulting fourth combustion stream as well as, optionally, a fifthstream if a refractory unit is included with the second reactionefficiency optimization module 800′.

In effect, combustion streams will be sequentially generated dependingon the number of reaction efficiency optimization modules desired toarrive at a combustion stream for receipt by the N^(th) reactionefficiency optimization module. Those of ordinary skill in the art willreadily recognize that the laminar air intake stream can meet with anydesired number of combustion streams before lastly defining an N^(th)combustion stream. In at least one embodiment, the N^(th) combustionstream 800″ exits the laminar burner system 5 to define an energy outputfor use with an energy consumption system.

Optionally, the N^(th) reaction efficiency optimization module 800″ orany other reaction efficiency optimization module between the N^(th)reaction efficiency optimization module 800″ and the first reactionefficiency optimization module 800 is releasable from the first reactionefficiency optimization module 800. As such, interchangeabilityfacilitates a desired combustion efficiency output as well as ease ofmaintenance, repair, and transportation of the laminar burner system 5.

With reference to FIG. 5, a combustion efficiency control system 888 isintegrated with a laminar burner system 5. The combustion efficiencycontrol system 888 facilitates operation of a laminar burner system 5.In at least one embodiment, the combustion efficiency control systemprovides operational instructions for optimizing a high efficiencycombustion process in the delivery of thermal energy to an energyconsumption system 75 coupled to the laminar burner system 5.

For measuring and controlling a laminar air-intake stream, thecombustion efficiency control system 888 features an air flow sensorarrangement. The air flow sensor arrangement includes a supply inletsensor 73 and an air delivery controller 126 electrically coupled to thesupply inlet sensor 73. Although those of ordinary skill in the art willreadily recognize other positions, the supply inlet sensor 73, in oneembodiment, is electrically coupled and positioned adjacent to an airreceiving port 28 and the air delivery controller 126. The air deliverycontroller 126 is positioned adjacent to a damper 21 and a blower 25 ofthe laminar air delivery system 22.

In operation, the air flow sensor arrangement measures laminar air flowand emits an efficiency signal 88 including laminar air flow inputvalues. The air flow sensor arrangement receives efficiency signals 88from the combustion efficiency control system 888 including laminar airflow control signals. On receiving laminar air flow control signals, thesupply inlet sensor 73 and the air delivery controller 126, each of theair flow sensor arrangement, cooperate to control flow of the laminarair intake stream by adjusting the damper 21 and the blower 25.

For measuring and controlling a laminar air-intake stream, thecombustion efficiency control system 888 further includes a combustionsensor/controller unit 37. The combustion sensor/controller unit 37 ispositioned adjacent to the injector device 31 and fixed to the alignmentplate 72 with respect to the alignment axis 777. The sensor/controllerunit 37 is electrically coupled to the pilot unit 35 and the inletactuators 89 for variably closing the respective inlet ports 29.

The sensor/controller unit 37 emits and receives efficiency signals 88associated with the combustion efficiency control system 888. In oneembodiment, the sensor/controller unit 37 and/or the fuel controllerunit 74 measure the burn efficiency of the laminar air intake stream andthe fuel within the mixing chamber during formation of a firstcombustion stream by measuring the injection of the volume by squareinch, Oz/in², which should be lower when compared with other highefficiency burners. In one embodiment, the sensor/controller unit 37and/or the fuel controller unit 74 detect various predeterminedwavelengths of light indicative of the flame color of a first combustionstream formed within the mixing chamber 44 as the laminar air intakestream and the fuel are combined and emits an efficiency signal 88including light wavelength data. Additionally, the combustion efficiencycontrol system 888 emits an efficiency signal 88 for receipt by thesensor/controller unit 37 or, alternatively, directly by the inletactuators 89 to automatically adjust the laminar air intake stream tocorrespondingly change combustion efficiency within the mixing chamber44.

Similarly, for measuring and controlling a fuel flow, the combustionefficiency control system 888 further includes a fuel controller unit74. The fuel controller unit 74 includes fuel passageway valve 74 a anda fuel flow sensor module 74 b. The fuel passageway valve 74 a iscoupled to the fuel passageway 34 to variably supply fuel to thecombustion manifold 70. The fuel flow sensor module 74 b is coupled tothe fuel passageway 34 and the fuel passageway valve 74 a. The fuel flowsensor module 74 b measures fuel flow and emits an efficiency signal 88including fuel flow input values. The combustion efficiency controlsystem 888 sends efficiency signals to the fuel controller unit 74 thatincludes control values to control fluid flow through the fuelpassageway 34 by variably operating the fuel passageway valve 74 a.

For measuring and controlling the combustion energy output of thelaminar burner system 5, the combustion efficiency control system 888further includes a burner output sensor module 76. As shown, the burneroutput sensor module 76 is positioned outside, adjacent to the burnersystem outlet 63. In operation, the burner output sensor module 76measures combustion energy output produced by the laminar burner system5. The measured combustion energy output includes measuring thecombustion efficiency of a series of combustion streams that passthrough a combustion manifold 70. In one embodiment, as shown in FIG. 7,the burner output sensor module 76 measures burn efficiency of thelaminar air intake stream and the fuel traveling from the air receivingport 28 and supply input module 20 through a combustion manifold 70 thatincludes an air-fuel mixing chamber system 40 and a plurality reactionefficiency optimization modules having a combination of stoichiometriccombustion and refractory units.

Operatively, the burner output sensor module 76 measures the combustionenergy output of the laminar burner system 5 and, as a result, emits anefficiency signal 88 to the combustion efficiency control system 888. Inat least one embodiment, the resulting efficiency signal 88 includescombustion output values.

The combustion efficiency control system 888 compares combustion outputvalues and generates an efficiency signal 88 having a combination of airand fuel control data. A combination of the fuel controller unit 74, thesensor/controller unit 37, the inlet actuators 89, and the air flowsensor arrangement receive efficiency signals 88 from the combustionefficiency control system 888 that include control values for variablyoperating the fuel passageway valve 74 a to control fuel flowtherethrough and/or the air delivery controller 126, the blower 25, andat the inlet ports 29 to control air intake streams therethrough. In oneembodiment, the combustion efficiency control system 888 emits anefficiency signal 88, for automatically adjusting the laminar air intakestream to correspondingly change combustion efficiency. On receivinglaminar air flow control signals, the flow sensor arrangement engagesthe supply inlet sensor 73 and the air delivery controller 126 tocooperatively control flow of the laminar air intake stream by adjustingthe damper 21 and the blower 25, respectively.

As shown in FIG. 5, the combustion energy output is received by theenergy consumption system 75 and applied to a variety of industrialapplications. The energy consumption system 75 includes an inlet forreceiving the combustion energy output from the laminar burner system 5.As shown in FIG. 5, the energy consumption system 75 further includes anoutlet. A system output sensor module 77 is coupled to the energyconsumption system outlet. The system output sensor module 77 measuresenergy used by the energy consumption system 75. As such, the measuredused energy values are incorporated with an efficiency signal 88 foremission by the system output sensor module 77 to the combustionefficiency control system 888.

The combustion efficiency control system 888 compares used energy valuesfrom the system output sensor module 77 with combustion output valuesfrom the laminar burner system 5. Accordingly, the combustion efficiencycontrol system 888 generates an efficiency signal 88 having acombination of air and fuel control data for variably adjusting thecombustion energy output efficiency of the laminar burner system 5 asapplied to the energy consumption system 75.

Further referring to FIG. 5, the combustion efficiency system 888includes an operating unit 80 for operative engagement with the laminarburner system 5. In one embodiment, the operating unit 80 is a portabledevice, for example, among others, a hand-held electronic device. Inanother embodiment, the operating unit 80 is a stationary device.

The combustion efficiency system 888 further includes anemitter/receiver 83 coupled to the operating unit 80. In one embodiment,the emitter/receiver 83 receives fuel and air flow input values includedwith the corresponding efficiency signal 88 for use by the operatingunit 80. Similarly, in one embodiment, the emitter/receiver 83 receivesan efficiency signal 88 including the burn efficiency values of fuel andlaminar air within the mixing chamber 44 to form a first combustionstream. In one embodiment, the emitter/receiver 83 receives anefficiency signal 88 including combustion energy output produced by thelaminar burner system 5. In one embodiment, the emitter/receiver 83receives an efficiency signal 88 including values associated with energyused by the energy consumption system 75.

With specific reference to FIG. 5, the operating unit 80 includes atleast one processor 80 a and at least one corresponding memory 80 b. Theoperating unit 80 includes an input/output interface 84 coupled to theprocessor 80 a, the memory 80 b, and the emitter/receiver 83. As shownin FIG. 5, the operating unit 80 further includes a display 82 coupledto the input/output interface 84, the processor 80 a, the memory 80 b,and the emitter/receiver 83.

In operation, in one embodiment, the input/output interface 84 receivesa manual input thereon. In one embodiment, the input/output interface 84and the display 82 cooperate to receive and display an output generatedby the operating unit 80, such as, among others, providing thecombustion efficiency of the laminar burner system 5 in real time on thedisplay 82.

In one embodiment, the processor 80 a and the corresponding memory 80 bfrom the operating unit 80 operatively cooperate to compare laminar airflow and fuel flow input values with combustion output values. In oneembodiment, the laminar air flow and fuel flow input values are comparedwith predetermined combustion output values stored in the memory 80 b togenerate the efficiency signal 88 having a combination of air and fuelcontrol data. Alternatively, the operating unit 80 compares the fuel andair flow input values with stored combustion values collected fromefficiency signals 88 received from sensors positioned about the laminarburner system 5.

In one embodiment, the laminar air flow and fuel flow input values arecompared with combustion output values collected in real time from theburner output sensor module 76, the system output sensor module 77, thesensor/controller unit 37 or any other well known sensor in the industryrecognized by those of ordinary skill in the art for measuringcombustion. For example, among others, the operating unit 80 comparesthe fuel and air flow input values with combustion output valuesprovided by the efficiency signal 88 received from the burner outputsensor module 76 to generate the efficiency signal 88 having acombination of air and fuel control data.

The combustion efficiency control system 888 generates an efficiencysignal 88 having a combination of air and fuel control data.Accordingly, the efficiency signal 88 provides control information forrecalibrating air and fuel flows with respect to a desired combustionefficiency. In one embodiment, the operating unit 80 generates and emitsan efficiency signal 88 having a combination of air and fuel controldata for receipt by a fuel controller unit 74, an air deliverycontroller 126, and a combustion sensor/controller unit 37 for selectiveactivation thereof to control the supply of fuel and laminar air intakestreams to the combustion manifold 70.

A method for controlling combustion efficiency for a laminar burnersystem 150 is appreciated as follows. As shown in FIG. 5, the laminarburner system 5 delivers thermal energy to an energy consumption system75 coupled thereto. Referring to FIG. 6, the method 150 begins as airand fuel flow sensor measurements are obtained from the laminar burnersystem 5. In step 154, the laminar burner system 5 emits efficiencysignals including flow input values to the combustion efficiency controlsystem 888.

Referring to step 156, sensors positioned about the laminar burnersystem 5 and, optionally, the energy consumption system 75 measurecombustion efficiency of the laminar burner system 5. Accordingly, thesensors emit efficiency signals 88 including combustion output values tothe combustion efficiency control system 888.

In one exemplary method, steps 160-166 provide various means forcollecting combustion output values with the laminar burner system ofFIG. 5 although those of ordinary skill in the art will readilyrecognize other means for collecting combustion output values.Specifically, in step 160, the sensor/controller unit 37 obtainscombustion measurements for incorporation with an efficiency signal 88.In step 162, the burner system output module 76 obtains burner systemcombustion output measurements for incorporation with an efficiencysignal 88. Similarly, in step 166, system output sensor module 77obtains system energy output measurements for incorporation with anefficiency signal 88.

In step 170, the respective sensors emit efficiency signals 88 includingoutput values. The combustion efficiency control system 888 receivesevaluates the efficiency signals 88. In one exemplary method, theprocessor 80 a in step 172 compares efficiency signal values with storedvalues in memory 80 b, for example, among others, predetermined valuesstored in memory or values previously collected from the sensor outputvalues that are stored in memory. Alternatively, the processor 80 a instep 174 compares efficiency signal values for air and fuel flow inputwith combustion output and energy consumption values each collected bythe respective sensors to thus compare real time values.

As a result, in step 176, the combustion efficiency control system 888emits efficiency signals 88 including a combination of air and fuel flowcontrol data to the laminar burner system 5. In step 178, the laminarburner system 5 a adjusts for any combination of subsequent air and fuelflows based on the received efficiency signals 88.

Although the present invention has been described in detail, it shouldbe understood that various changes, substitutions, and alterations couldbe made hereto without departing from the spirit and scope of theinvention as defined by the appended claims.

We claim:
 1. A combustion efficiency control system comprising: alaminar air delivery system, the laminar air delivery system including ablower; an air flow sensor arrangement, the air flow sensor arrangementincluding an air delivery controller, the air delivery controllerelectrically coupled to the blower, the air flow sensor arrangementmeasures laminar air flow and emits an efficiency signal, the airdelivery controller receives the efficiency signal to control the flowof the laminar air intake stream by adjusting the blower; a combustionmanifold, the combustion manifold in fluid communication with thelaminar air delivery system; the laminar air delivery system, via theairflow sensor arrangement, provides a laminar air intake stream with acontrolled flow to the combustion manifold, the combustion manifoldincludes an air-fuel mixing chamber system, the air-fuel mixing chambersystem in fluid communication with the laminar air delivery system, andincludes a mixing chamber and an injector device extending within themixing chamber,  whereby fuel exits the injector device to mix with thelaminar air intake stream traveling along the air-fuel mixing chamber todefine a first combustion stream, and a stoichiometric combustion unit,the stoichiometric combustion unit in fluid communication with theair-fuel mixing chamber system, and includes a staging passageway and astoichiometric unit body,  whereby the laminar air intake streamtraveling along the staging passageway passes through the firstcombustion stream within the stoichiometric unit body to define a secondcombustion stream; an air receiving port, the air receiving portdiffuses air received from the laminar air delivery system to direct aplurality of laminar air intake streams to the combustion manifold; anda plurality of interchangeable reaction efficiency modules coupled tothe stoichiometric combustion unit, at least one interchangeablereaction efficiency module of the plurality of interchangeable reactionefficiency modules receiving the second combustion stream.
 2. Thecombustion efficiency control system according to claim 1 wherein theplurality of interchangeable reaction efficiency modules define a thirdcombustion stream
 3. The combustion efficiency control system accordingto claim 2 wherein the plurality of interchangeable reaction efficiencymodules receive the plurality of air intake streams.
 4. The combustionefficiency control system according to claim 3 wherein at least oneintake streams of the plurality of air intake streams meet with thethird combustion stream to define a fourth combustion stream.
 5. Thecombustion efficiency control system according to claim 1 wherein thelaminar air delivery system includes a damper, the damper in fluidcommunication with the blower.
 6. The combustion efficiency controlsystem according to claim 5 wherein the damper is electrically coupledto the blower and the air delivery controller, the air deliverycontroller receives the efficiency signal to control the flow of thelaminar air intake stream by adjusting the damper.
 7. The combustionefficiency control system according to claim 5 further comprising asensor/controller, the sensor controller coupled to the damper.
 8. Thecombustion efficiency control system according to claim 7 wherein thesensor/controller receives a predetermined wavelength of light to modifyair supply by controlling the movement of the damper.
 9. A combustionefficiency control system comprising: a laminar air delivery system, thelaminar air delivery system including a damper; an air flow sensorarrangement, the air flow sensor arrangement including an air deliverycontroller, the air delivery controller electrically coupled to thedamper, the air flow sensor arrangement measures laminar air flow andemits an efficiency signal, the air delivery controller receives theefficiency signal to control the flow of the laminar air intake streamby adjusting the damper; a combustion manifold, the combustion manifoldin fluid communication with the laminar air delivery system; the laminarair delivery system, via the airflow sensor arrangement, provides alaminar air intake stream with a controlled flow to the combustionmanifold, the combustion manifold includes an air-fuel mixing chambersystem, the air-fuel mixing chamber system in fluid communication withthe laminar air delivery system, and includes a mixing chamber and aninjector device extending within the mixing chamber,  whereby fuel exitsthe injector device to mix with the laminar air intake stream travelingalong the air-fuel mixing chamber to define a first combustion stream,and a stoichiometric combustion unit, the stoichiometric combustion unitin fluid communication with the air-fuel mixing chamber system, andincludes a staging passageway and a stoichiometric unit body,  wherebythe laminar air intake stream traveling along the staging passagewaypasses through the first combustion stream within the stoichiometricunit body to define a second combustion stream; and a plurality ofinterchangeable reaction efficiency modules coupled to thestoichiometric combustion unit, at least one interchangeable reactionefficiency module of the plurality of reaction efficiency modulesreceiving the second combustion stream.
 10. The combustion efficiencycontrol system according to claim 9 further comprising an air receivingport, the air receiving port diffuses air received from the laminar airdelivery system to direct a plurality of laminar air intake streams tothe combustion manifold.
 11. The combustion efficiency control systemaccording to claim 10 wherein the plurality of interchangeable reactionefficiency modules receive the plurality of air intake streams.
 12. Thecombustion efficiency control system according to claim 10 wherein atleast one intake streams of the plurality of air intake streams meetswith the third combustion stream to define a fourth combustion stream.13. The combustion efficiency control system according to claim 9wherein the laminar air delivery system includes a blower, the blower influid communication with the damper.
 14. The combustion efficiencycontrol system according to claim 13 wherein the blower is electricallycoupled to the damper and the air delivery controller, the air deliverycontroller receives the efficiency signal to control the flow of thelaminar air intake stream by adjusting the blower.
 15. The combustionefficiency control system according to claim 13 further comprising asensor/controller, the sensor controller coupled to the blower.
 16. Thecombustion efficiency control system according to claim 15 wherein thesensor/controller receives a predetermined wavelength of light to modifyair supply by controlling the fluid movement produced by the blower. 17.The combustion efficiency control system according to claim 9 furthercomprising an air receiving port, the air receiving port diffuses airreceived from the laminar air delivery system to direct a plurality oflaminar air intake streams to the combustion manifold.
 18. A combustionefficiency control system for a laminar burner system, the laminarburner system delivering thermal energy to an energy consumption systemcoupled thereto, the combustion efficiency control system comprising: anair flow sensor arrangement, the air flow sensor arrangement positionedadjacent to an air receiving port, the air flow sensor arrangementmeasuring laminar air flow and emitting an efficiency signal includinglaminar air flow input values; a fuel flow sensor module, the fuel flowsensor module coupled to a fuel passageway, the fuel flow sensor modulemeasuring fuel flow and emitting an efficiency signal including fuelflow input values; a burner output sensor module, the burner outputsensor module positioned adjacent to a burner system outlet, wherein theburner sensor module measures combustion energy output produced bylaminar burner system, the burner output sensor module measuringcombustion and emitting an efficiency signal including combustion energyoutput values; an operating unit, the operating unit compares laminarair flow and fuel flow input values with combustion output values togenerate an efficiency signal having a combination of air and fuelcontrol data; a sensor/controller unit, the sensor/controller unitcoupled to an air-fuel mixing chamber system, the sensor/controller unitmeasures the burn efficiency of laminar air and fuel within air-fuelmixing chamber system; and a pilot unit coupled to the sensor/controllerunit, the pilot unit is engaged by the sensor/controller unit to ignitethe nearby fuel based on predetermined wavelengths of light detected bythe sensor/controller unit.
 19. The combustion efficiency control systemaccording to claim 18 wherein the pilot unit is disengaged by thesensor/controller as the sensor controller detects a predeterminedwavelength of light.
 20. The combustion efficiency control systemaccording to claim 18 wherein, based on reading wavelengths of lightindicative of a successful combustion, the sensor/controllercontinuously changes the pilot unit's period of operative engagement.